Method and system for rapid construction of structurally reinforced concrete structures using prefabricated assemblies and method of making the same

Abstract

The present invention includes prefabricated assemblies which are assembled on a construction site to provide a permanent concrete mold with integrated structural reinforcement and structural splices for cast-in-place concrete structures. The invention enhances the quality of the cast concrete structure while lowering the cost of construction and construction time. Described herein is a column form assembly, a column closure panel assembly, a beam form assembly, and a slab form assembly which are used to construct cast in place structurally reinforced concrete columns, beams, and floor slabs with minimal form work and construction site logistics. Also described herein are a method of assembly of said structures and a method of fabricating said assemblies.

Claims

1. A construction method comprising the following steps: (a) providing prefabricated assembly components comprising a column form assembly and a column closure panel assembly, wherein the column form assembly is an elongate member C-shaped in cross-section comprising internal slots running longitudinally along a length of the column form assembly on opposing sides thereof, the internal slots constituting keying geometries configured to receive the column closure panel assembly and restrict improper assembly on site; (b) standing the column form assembly on a slab at a construction site; (c) inserting the column closure panel assembly into the column form assembly standing on the slab to provide a column form; (d) casting concrete in the column form to provide a column; (e) repeating steps (a) through (d) at least once so as to provide a plurality of columns; (f) positioning prefabricated beam form assemblies on the columns formed in steps (a) through (e); and (g) positioning prefabricated slab form assemblies on the prefabricated beam form assemblies positioned on the columns so as to provide a cast in place concrete structure.

2. The method of claim 1, wherein: (a) the column form assembly comprises a beam form assembly receiving surface to receive only the beam form assembly; and (b) the beam form assembly comprises a slab form assembly receiving surface to receive only the slab form assembly.

3. A concrete structure prepared by the method of claim 1, wherein the concrete structure is a multi-story building.

4. A concrete structure prepared by the method of claim 1, wherein the concrete structure is a single-story building.

5. The method of claim 1, wherein the method is conducted without temporary fastening, strapping or clamping provisions.

6. The method of claim 1, wherein the walls of the concrete structure are the column forms.

7. The method of claim 1, wherein all walls and all columns of the concrete structure are formed from identical prefabricated column form assemblies and identical prefabricated column closure panel assemblies.

8. The method of claim 1, wherein the concrete structure is a single-story building.

9. The method of claim 1, wherein the concrete structure is a multi-story building.

10. The method of claim 1, wherein at least one of the column form assembly, the column closure panel assembly, the beam form assemblies and the slab form assemblies comprises a shaped form and integrated structural reinforcement, wherein the shaped form comprises at least one formed material selected from the group consisting of concrete, fiber reinforced plastic, and molded plastic.

11. The method of claim 10, wherein the integrated structural reinforcement is applied to the shaped form and partially exposed, allowing for subsequent reinforcement of the concrete cast in the permanent concrete mold.

12. The method of claim 10, wherein the integrated structural reinforcement is applied to the shaped form by casting.

13. The method of claim 10, wherein the integrated structural reinforcement is applied to the shaped form by fastening.

14. The method of claim 10, wherein the integrated structural reinforcement comprises a material selected from the group consisting of steel bars, steel wire, carbon fiber reinforced composite bars, glass fiber reinforced composite bars, aramid fiber reinforced composite bars, bamboo, and perforated steel sheet.

15. The method of claim 10, wherein the shaped form comprises a concrete formulation having a density no greater than 160 pounds per cubic foot and comprising: cement; water; a reinforcing matrix; and an aggregate comprising at least one member selected from the group consisting of an expanded polymeric foam, hollow glass spheres, hollow ceramic spheres, expanded silica, fumed silica, expanded shale, expanded clay, foamed glass, vermiculite and perlite.

16. The method of claim 15, wherein the reinforcing matrix comprises at least one member selected from the group consisting of glass fiber, polyethylene fiber, polyvinylacetate fiber, polypropylene fiber, polyamide fiber and steel wire.

17. A construction method comprising the following steps: (a) providing prefabricated assembly components comprising a column form assembly and a column closure panel assembly; (b) standing the column form assembly on a slab at a construction site without temporary fastening, strapping or clamping provisions; (c) inserting the column closure panel assembly into the column form assembly on the slab to provide a column form, wherein the column closure panel is received within internal slots running longitudinally along a length of the column form assembly, the internal slots constituting keying geometries configured to restrict improper assembly on site; (d) casting concrete in the column form to provide a column; (e) repeating steps (a) through (d) at least once; (f) positioning prefabricated beam form assemblies on columns formed in steps (a) through (e); and (g) positioning prefabricated slab form assemblies on the beam form assemblies so as to provide a cast in place concrete structure.

Description

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

(1) The invention will be described in conjunction with the following drawings in which like reference numerals designate like elements and wherein:

(2) FIG. 1 shows perspective views of embodiments of typical building structures which utilize the present invention.

(3) FIG. 2A shows a perspective view of a column form assembly which receives a column closure panel assembly.

(4) FIG. 2B shows a perspective view of alternative column form assemblies which receive a column closure panel assembly.

(5) FIG. 3A shows a perspective view of a column closure panel assembly with integral structural reinforcement which is inserted into said column form assembly.

(6) FIG. 3B shows a perspective view of a column form assembly with integral structural reinforcement which receives a column closure panel assembly.

(7) FIG. 4 shows a perspective view of a prefabricated structural reinforcement foundation cage, and is commonly used by those skilled in the art.

(8) FIG. 5 shows a perspective view of a beam form assembly consisting of a precast panel with integrated beam structural reinforcement and a reinforcement extension.

(9) FIG. 6 shows a perspective view of a slab form assembly consisting of a precast panel with horizontal reinforcement extensions.

(10) FIG. 7 shows a perspective view of the step of setting a foundation cage into a prepared building site.

(11) FIG. 8 shows a perspective view of the step of forming a concrete slab on grade over said foundation cages with exposed vertical column reinforcement.

(12) FIG. 9 shows a perspective view of the step of placing said column form assemblies onto said concrete slab in alignment with said vertical column reinforcement.

(13) FIG. 10 shows a perspective view of the step of inserting said column closure panel assembly into said column form assembly.

(14) FIG. 11 shows a perspective view of the step of pouring concrete into the cavity formed by said column form assembly and said column closure panel assembly.

(15) FIG. 12 shows a perspective view of the step of placing said beam form assembly onto said column form assembly and said column closure panel assembly.

(16) FIG. 13 shows a perspective view of the step of placing said slab form assemblies onto said beam form assemblies as to traverse the gaps between said beam form assemblies.

(17) FIG. 14 shows a perspective view of the step of forming a concrete slab over the integral structural reinforcement of said closure panel assemblies, beam form assemblies, and slab form assemblies.

(18) FIG. 15 shows a perspective view of the step of placing said column form assemblies onto concrete slab formed of said beam form and said slab form assemblies.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

(19) The present invention is typically applied to the construction of single story and multi-story buildings, such as single-family houses, multi-family residences, commercial properties, and other buildings in which humans can reside, work, gather or the like. Thus, the expression prefabricated assembly component as used herein refers to structural elements of such buildings and as such, does not encompass building blocks or structural components for toys and miniature models. FIG. 1 depicts non-limiting examples of buildings, which utilize the present invention. Each building features a 001 slab on grade formed of steel reinforced concrete, which is familiar to those skilled in the art. The typical building is structured of features which are formed from assemblies and methods related to the present invention, such as structural columns 002, 003, structural beams 004, 005, slabs 006 and staircases 007. In addition, other precast structures unrelated to the present invention are typically used in such buildings. Structural columns formed in the typical building comprise a novel permanent formwork as an alternative to conventional removable formwork used for cast in place concrete structures.

(20) Referring to FIGS. 2A and 3A, a column form assembly 020 is preferably cast of concrete reinforced with steel wire or bars; this column form assembly also incorporates a slot 022 and a keying geometry 021 which receives an additional column closure panel assembly 030 which incorporates a structural reinforcement 031 as well as a vertical reinforcement extension 032. This vertical reinforcement extension 032 facilitates a lap splice to an additional column form assembly 020 and column closure panel assembly 030. Lap splices made at grade 071 preferably occur at the foundation reinforcement extension, which is reinforced with a foundation cage 040, a common prefabricated component used by those skilled in the art to reinforce concrete footings for columns and the like, and is not part of the present invention. See FIG. 7.

(21) FIG. 2B depicts alternative shapes 023, 024, 025 the column form assembly may take. Alternatively shaped and proportioned column form assemblies are within the scope of the present invention.

(22) FIG. 3B depicts an alternative column form assembly which integrates partially exposed structural reinforcement 031. While the preferred embodiment of the invention integrates the exposed structural reinforcement 031 into the column closure panel assembly 030, an alternative embodiment of the invention integrates this exposed structural reinforcement 031 into the column form assembly 035.

(23) The preferred embodiment of the invention utilizes keying geometries 021, 033, as shown in FIGS. 2A and 3A. Another embodiment of the invention does away with these keying geometries and allows for a column closure panel assembly to be composed of a sheet stock material such as plywood, wood, sheet metal, concrete panel, glass, or other materials of adequate stiffness to withstand the static pressure of the concrete infill.

(24) In the preferred embodiment of the invention, the geometry of the column form assembly 020, 023, 024, 025 is designed to accept an inserted column closure panel assembly by means of an integral slot 022, eliminating the need for temporary clamping and strapping.

(25) In addition to columns, the present invention facilitates the construction of beams and floor slabs in single and multi-story constructions. As shown in FIG. 5, a beam is made up of a beam form assembly 050 which incorporates structural reinforcement 051 and a hook reinforcement extension 052. Slabs are formed by spanning the space between beams using a slab form assembly 060, which consists of a cast panel with integral structural reinforcement 062 and a horizontal reinforcement extension 061. See FIG. 6.

(26) Constructing buildings using the present invention involves preparing the site for a foundation and placing the necessary foundation components, such as foundation cage 040. This foundation is designed for the specific site and soil conditions, and is formed of components common to those skilled in the art. A slab on grade 080 is formed over foundation cages 040 to form the ground floor, which preferably incorporates reinforcement extensions 041 from the foundation cages, as shown in FIG. 8. A column form assembly 090 is then placed at each reinforcement extension 041 as shown in FIG. 9, and a column closure panel assembly 030 with an integral vertical column reinforcement 032 is then inserted into the column form assembly 090, creating a cavity 110 into which concrete is poured (FIG. 11). Beam form assemblies 120 are then placed atop the completed columns such that the hook reinforcement extension 052 is in alignment with the vertical column reinforcement 032. See FIGS. 10, 11 and 12.

(27) In a preferred embodiment of the invention, a hook reinforcement extension 052 is used to create a structural splice between the beam and column. Variations on reinforcement extensions common among those skilled in the art, such as loop extensions or straight extensions, may be used in the context of the present invention as well.

(28) Completing the formation of beams involves forming a continuous slab, which may incorporate a spanning slab formed of a slab form assembly 130. See FIG. 13. This spanning slab form assembly 130 interfaces to the structural reinforcement 051 of the beam form assembly 050 with horizontal reinforcement extensions 061, which may also be linked together in the field before pouring concrete. In addition, shoring 131 may also provide additional structural support while pouring beams and slabs. It is obvious to one skilled in the art that atria may be formed in the building by excluding a slab form assembly 130. After shoring, slab form assemblies 130, and beam form assemblies 120 are placed, concrete can be poured to form a floor slab 140 which incorporates completed beams and slab. See FIG. 14. Construction may then progress to additional floors using a similar process, beginning with the placement of additional column form assemblies 150. See FIG. 15.

(29) In certain embodiments, other systems such as electrical, plumbing, communications, and heating, ventilation and air conditioning connections are incorporated into prefabricated structural elements.

(30) In certain embodiments, the compressive strength of the concrete available in the field is understood to be significantly lower than the concrete typically used for cast in place structures due to poor quality control or poor craftsmanship. In such embodiments, the structural reinforcement and precast structural elements are designed to handle necessary structural loads anticipating that the infill concrete exhibits a predetermined poor compressive strength. The surface finish and quality of the concrete structure is not compromised since the exposed portions of the concrete consist of precast portions of structural elements.

(31) In certain embodiments, the precast portion of the beam form assembly, slab form assembly, column form assembly, and column closure panel assembly are composed of cast concrete. In a further embodiment, this concrete comprises a lightweight formulation weighing no more than 100 or 160 pounds per cubic foot. In a further embodiment, this lightweight concrete formulation includes an aggregate comprising at least one of an expanded polymeric foam, hollow glass spheres, hollow ceramic spheres, expanded silica, fumed silica, expanded shale, expanded clay, foamed glass, vermiculite, and perlite, a combination of said aggregates, or other lightweight aggregates commonly employed by those skilled in the art. In a yet further embodiment, a reinforcing matrix is incorporated into the concrete mixture, comprising at least one member selected from the group consisting of glass fiber, polyethylene fiber, polyvinylacetate fiber, polypropylene fiber, polyamide fiber and steel wire.

(32) In another embodiment, the beam form assembly, slab form assembly, column form assembly, and column closure panel assembly may be substantially formed of alternative materials to precast concrete, including but not limited to materials such as fiber reinforced plastic (FRP), roto-molded plastic, foamed plastic, molded foam, and other composite materials.

(33) In another embodiment, the prefabricated components incorporate finishing materials which are set in place using said cast concrete. In certain embodiments, the column form assembly incorporates a structural reinforcement in the prefabrication step.

(34) In certain embodiments, the structural reinforcement incorporated into the beam form assembly, slab form assembly, and column closure panel assembly comprises steel (e.g., a perforated steel sheet), carbon fiber reinforced composite, fiberglass reinforced composite, aramid fiber reinforced composite, bamboo, or another structural reinforcement of high tensile strength commonly used by those skilled in the art.

(35) In certain embodiments, said standardized column form assemblies, closure panel assemblies, beam form assemblies, and slab form assemblies incorporate keying geometries 021, 033 which allow components to be combined in only one fashion on site. The specific shape and size of these keying geometries may vary without departing from the spirit of the invention. In certain embodiments, said standardized elements and assemblies can be arranged in any fashion, limited only to the number of vertical floors, without being re-engineered for building specific structural conditions.

(36) While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.